Repair manual KTM 125 / 200
Art No 3.206.005 -E
– Position the sliding gauge on the cylinder and turn the piston to TDC
by turning the flywheel. Read the value indicated by the sliding
gauge.
125 ccm up to model 2000: dimension „X“ = 0.60 mm (0.024 in)
125 ccm model 2001 onwards: dimension „X“ = 0.0 mm (0.0 in)
200 ccm up to model 2002: dimension „X“ = 0.55 mm (0.022 in)
200 ccm model 2003 onwards: dimension „X“ = 0.0 mm (0.0 in)
– Adjust dimension „X“ by adding or removing cylinder base gaskets.
NOTE: Adding of cylinder base gaskets increases and removing cylinder
base gaskets reduces dimension „X“.
– Mount the two remaining collar nuts at the cylinder base and tighten
all 4 collar nuts with 30 Nm (22 ft.lb.).
Adjusting the control flap (dimension „Z“)
NOTE: Dimension „Z“ is the distance between the lower edge of the
control flap and the upper edge of the cylinder, measured in the middle
of the exhaust port.
125 SX/EXC/EXE up to model 2000: Z = 42.0 mm + 0.2/- 0.6 mm
125 SX/EXC/EXE model 2001: Z = 42.5 mm + 0.2/- 0.6 mm
125 SX/EXC from model 2002: Z = 43 mm + 0.2/- 0.6 mm
200 MXC/EXC up to model 2001: Z = 46.0 mm + 0.2/- 0.6 mm
200 MXC/EXC model 2002: Z = 46,5 mm + 0.2/- 0.6 mm
200 MXC/EXC from model 2003: Z = 47 mm + 0.2/- 0.6 mm
200 SX from model 2003: Z = 46 mm + 0.2/- 0.6 mm
– Loosen locking bolt
1 only 2 turns .
– Adjust the depth gauge to the indicated value and fix it in this
position.
– Insert the depth gauge into the cylinder.
–Turn the bearing carrier
2 at the clutch cover so that the control flap
rests against the depth gauge.
–Tighten the locking bolt
1 to prevent the bearing carrier from
turning
– Mount the hexagon cap nut
3 of the centrifugal timer together with
a new seal ring.
!
CAUTION
!
WHEN MOUNTING THE HEXAGON CAP NUT MAKE SURE THAT THE BEARING CARRIER
OF THE CENTRIFUGAL TIMER IS NOT TURNED ANY MORE
. OTHERWISE DIMENSION
„Z“ MUST BE ADJUSTED ONCE AGAIN.
Cylinder head
– Clean the sealing surfaces of the cylinder and the cylinder head.
– Insert a new O-ring into the corresponding groove of the cylinder
and mount a new cylinder head gasket.
NOTE: on 125 SX/EXC-engines from model 2002 onwards an O-ring is
used instead of the gasket.
– Mount the cylinder head with the water nozzle facing the exhaust
side and slightly turn it back and forth to prevent crushing of the
O-ring.
– Mount the collar bolts with new copper gaskets and tighten them
crosswise, taking 3 turns to achieve the total tightening torque of
18 Nm (13 ft.lb.).
– Initially, the bolts should only be tightened until the first slight
resistance is felt.
– Insert the spark plug and tighten with 20 Nm (15 ft.lb.).
X
6-10C
1
2
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